ballard sport aircraft ltd. · ballard sport aircraft ltd. pelican sport 450 s 5 ... instruments...

Ballard Sport Aircraft Ltd.

THE PELICAN SPORT 450 S

OPERATOR MANUAL

All rights reserved: Ballard Sport Aircraft Ltd. 2696 rue du Pimbina, Sherbrooke, Québec, Canada, J1R 0G3 Phone: 819-563-5847 Fax: 819-829-5677 www.ballardsportaircraft.com

Revision 2008-01

Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.

© Copyright 2007-2008 Ballard Sport Aircraft Ltd. – All rights reserved --.

http://www.ballardsportaircraft.com/

Ballard Sport Aircraft Ltd.

Table of content 1 Pelican Sport 450 Technical descriptive..................................................................................................5

1.1 General ..............................................................................................................................................5 1.2 Technical description ........................................................................................................................5 1.3 3-view drawing..................................................................................................................................7 1.4 Technical specifications and performance ........................................................................................8

1.4.1 Spécifications...........................................................................................................................8 1.4.2 Performance with BRP Rotax 912ULS ...................................................................................8 1.4.3 Performance on floats with BRP Rotax 912UL.......................................................................8

2 FLIGHT ENVELOPE .............................................................................................................................9 3 PLACARD SPEEDS AND LIMITATIONS.........................................................................................10 4 PLACARDS AND INSTRUMENT MARKINGS................................................................................11 5 POWERPLANT OPERATING SPEEDS AND LIMITS......................................................................11

5.1 AIRSPEED INDICATOR MARKINGS.........................................................................................12 5.2 WEIGHT LIMITS AND FLIGHT LOAD FACTOR LIMITS .......................................................12 5.3 CENTER OF GRAVITY LIMITS..................................................................................................12

6 WEIGHT AND BALANCE..................................................................................................................13 6.1 WEIGHT AND BALANCE CHECK .............................................................................................13 6.2 PROCEDURE, SAMPLE CALCULATION AND DATA.............................................................14 6.3 WEIGHT AND BALANCE CALCULATIONS ............................................................................16

7 NORMAL PROCEDURES...................................................................................................................18 7.1 PRE-FLIGHT INSPECTION..........................................................................................................18 7.2 ENGINE PRE-START VERIFICATION.......................................................................................20 7.3 START............................................................................................................................................20 7.4 CHECK BEFORE TAXIING .........................................................................................................20 7.5 TAXI ...............................................................................................................................................20 7.6 RUN-UP OF PRE-TAKE-OFF CHECK.........................................................................................21 7.7 TAKE-OFF .....................................................................................................................................22 7.8 ENGINE STOP ...............................................................................................................................22

AIRFRAME MAINTENANCE GUIDE.......................................................................................................23 1 MAINTENANCE OF COMPOSITE - General ..................................................................................23 2 MAINTENANCE OF FABRIC - GENERAL.......................................................................................24 3 HARDWARE........................................................................................................................................24 4 MAINTENANCE OF STEEL PARTS - General..................................................................................25 5 MAINTENANCE OF ALUMINIUM PARTS - General .....................................................................25 6 ACCESSORIES - General.....................................................................................................................25 MAINTENANCE SCHEDULE ....................................................................................................................26 1 Check before first flight:........................................................................................................................26 2 Check after initial 10 hours: ..................................................................................................................26 3 Check after initial 25 hours....................................................................................................................27 4 Check at every 50 hours ........................................................................................................................27 5 100 hours or annual inspection:.............................................................................................................27 6 WINTER OPERATION........................................................................................................................32 CONFORMITY INSPECTION CHECK-LIST ............................................................................................33

Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.


Ballard Sport Aircraft Ltd. PELICAN SPORT 450 S

3 Ballard Sport Aircraft Ltd. 2696 du Pimbina, Sherbrooke, Qc, Canada J1R 0G3 Phone: 819 563-5847.


WARNING

While designed and tested to meet and exceed the TP10141 Design Standards for Advanced Ultralight

and Sportplane category airplanes, THIS AIRCRAFT IS NOT TYPE CERTIFICATED

AND ITS OPERATOR HAS THE SOLE RESPONSIBILITY OF ITS AIRWORTHINESS

Flying is fun only if you put safety first.




INTRODUCTION This operator’s and maintenance manual was put together only as a guide to the operation and maintenance of your Pelican. It does not cover all that is required to do or know to safely operate your airplane. Read it carefully and make sure you have the required skills and competence to safely operate your aircraft. Your comments and suggestions to improve this manual will always be welcome. Note: The Rotax engine operator manual should be considered as a part of this manual and supersedes any information given in Ballard Sport Aircraft’s manual relating to the operation and maintenance of the engine.




1 Pelican Sport 450 Technical descriptive

1.1 General Design Standard: TP 10141

The Pelican Sport 450 S is manufactured by : Aéronefs Sportifs Ballard Ltée. 2696 rue du Pimbina, Sherbrooke, Québec, Canada, J1R 0G3

1.2 Technical description General

The Pelican Sport 450 is a two place single-engine, high wing airplane of conventional configuration consisting of a composite fuselage and metal wings. It is equipped with a fixed tricycle landing gear.

Engine The engine is a BRP Rotax, Type 912 S, 4 cylinder, 4 stroke featuring opposed cylinders, dual electronic ignition, dry sump with oil pump, liquid cooled heads, and an integrated gearbox. It is equipped with a 12V/250 Watt generator, two Bing 32 mm carburettors, a 0,6 KW electric starter and a mechanical fuel pump. The Rotax 912 S develops 100 HP at 5800 RPM and 94 HP at 5500 RPM.

Instruments Airspeed indicator, altimeter, magnetic compass, engine tachometer, cylinder head temperature gauge, oil pressure gauge, oil temperature gauge, one electrical fuel gauge

Propeller

Three blade or four blade, ground adjustable.

Fuselage Vacuum molded composite structure consisting of a S-glass vinylester resin laminate with rigid PVC foam core.

Cockpit Two seats, side by side, foam seat cushions, dual sticks, dual pedals, center console, Lexan windshield and baggage compartment windows. The baggage compartment behind the seats has a capacity of 50 lbs. (23 kg) without a ballistic chute and 20 lbs (9 kg) with a ballistic chute. Three-points seat belts - shoulder harness system for both seats.

Wings The all-metal wing is a single-strut, single spar construction, covered with aluminum skins. Wing tips are made of molded fiberglass. The ailerons and flaps are fabric covered.

Tail The fin and the cantilever stabilizer are all aluminum construction, covered with aluminum skins. Rudder and elevators are made of aluminum structures covered with fabric. Elevator and rudder tips have molded fiberglass tips.




Controls

The airplane features a dual control stick system, dual rudder pedal system and differential braking system. Ailerons are deflected through a bellcrank/push-rod mechanism mounted on ball bearings. A torque tube connected to a mechanical lever in the console operates flaps. The ailerons deflect 12° with full flaps. Rudder and elevators are cable operated. The elevator trim is mechanically operated. Fixed trims are used for the rudder and the ailerons.

Flaps Mechanically operated by a Johnson bar - type lever located in the console. They offer 5 positions from 0° to 45°.

Elevator trim One elevator trim mechanically operated by a lever on the console.

Fuel system Fuel is stored in one 15 USG (60 li) composite tank located behind the seat.

Landing gear The main landing gear legs are made of heat-treated 4130-springsteel tubing. The system consists of a right and a left leg, connected by a center tube. Aluminium blocks bolted inside the aluminium gear box support the legs. The nosegear leg is made of 4130 tubing with an aluminium fork. A bungee chord provides the nosegear suspension. The nosewheel is steerable via push rods connected to the pedals and it locks in flight. The tail dragger is also available.

Wheels and brakes The main wheels are Matco 6 inch wheels and disk brakes with 15 * 600 tires. The nose wheel is an Azuza 6-inch wheel with a 13 * 600 tire.

Optional equipment (not included in empty weight) • Upholstery and Carpet • Cabin heat & ventilation system • Strobe and naviguation lights system • Speed fairings • Wheel pants • Propeller spinner • Radios • Ballistic recovery chute




1.3 3-view drawing

Balla

rd Sp

ort A

ircra

ft L

td.

Pélic

an S

port

450

F

98-0

1-27

3 v

iew

450




1.4 Technical specifications and performance

1.4.1 Spécifications

Wingspan: 9,75 m 32,0 ft Wing area: 10,9 m2 117,3 sq ft Wing loading: 41,2 kg/m2 8,44 lbs/sq ft Aspect ratio: 8,7 8,7 Lenght tricycle: 6,07 m 19,9 ft Fin height tricycle: 2,59 m 8,5 ft Cabin width (at hips): 1,02 m 40 in Cabin width (at elbows): 1,17 m 46 in Cabin headroom: 1,04 m 41 in Structural gross (+4.5/-2.5 limit load): 450 kg 990 lbs Structural gross (+4.0/-2.0 limit load): 523 kg 1 150 lbs Dry empty weight tricycle: [280:290] kg [615:638] lbs Baggage capacity (including parachute):23 kg 50 lbs Fuel capacity: 60 litres 15 USG

1.4.2 Performance with BRP Rotax 912ULS

Horsepower: 73,5 kW 100 HP Never exceed speed Vne: 228 km/h 123 kts Cruising speed 75%@6 500 ft: 205 km/h 110 kts Cruising speed 65%@6 500 ft: 195 km/h 105 kts Maximum range @65% no reserve: 725 km 450 sm Fuel consumption @65%: 15,5 L/h 4,1 gph Rate of climb, sea level: 7,6 m/s 1 500 fpm Service ceiling: 4 900 m 16 000 ft Stall speed (flaps up) C.A.S.: 70 km/h 38 kts Stall speed (flaps down) C.A.S.: 63 km/h 34 kts Take-off ground run: 90 m 300 ft Take-off over 50 ft (15 m) obstacle: 150 m 500 ft

1.4.3 Performance on floats with BRP Rotax 912UL

Horsepower: 59 kW 80 HP Never exceed speed Vne 228 km/h 123 kts Cruising speed 75%@6 500 ft: 195 km/h 105 kts Cruising speed 65%@6 500 ft: 185 km/h 100 kts Maximum range @65% no reserve: 1 000 km 635 sm Fuel consumption @65%: 14,4L/h 3,8 gph Rate of climb, sea level: 6,6 m/s 1 300 fpm Service ceiling: 4 900 m 16 000 ft Stall speed (flaps up) C.A.S.: 70 km/h 38 kts Stall speed (flaps down) C.A.S.: 63 km/h 34 kts Take-off ground run: 105 m 350 ft Take-off over 50 ft (15 m) obstacle: 185 m 600 ft




2 FLIGHT ENVELOPE

Va Vc VdVf

-3

Vd: 137 KEASVne:123 KEASVc: 98 KEASVa: 85 KEAS Vf: 70 KEAS

V KEAS140130120110100908070605040302010

n

5

-1

-2

0

4

3

2

1




3 PLACARD SPEEDS AND LIMITATIONS There should be a placard in clear view of the pilot stating: 1) NO AEROBATIC MANEUVERS, INCLUDING SPINS, APPROVED 2) Speed limit Indicated speed Notes

Vne (max speed) 123 kts Do not exceed this speed under any consideration

Vno (max level speed) 98 kts Do not exceed this speed except in smooth air and then only with caution

Va (manoeuver speed) 85 kts No full or abrupt control movements above this speed

Vf (max speed for flaps) 70 kts No flaps above this speed




4 PLACARDS AND INSTRUMENT MARKINGS The following information should be displayed in full view of the pilot. Aerobatics prohibited Limits: Maneuvering speed ( I.A.S.) 85 kts Structural gross weight 1150 lbs Flight load factors: Flaps up +4.0 / -2.0 Flaps down +2

5 POWERPLANT OPERATING SPEEDS AND LIMITS Refer to the engine manufacturer operator’s manual to fill out the following table. Instruments in the aircraft should be marked accordingly: Instrument Red line

(minimum limit) Green arc

(up to warn limit) Red line

(maximum limit)

Tachometer

Cylinder head temp

Oil pressure

Oil temperature

Exhaust gas temp

Water temp




5.1 AIRSPEED INDICATOR MARKINGS Marking I.A.S. value or range Significance

White arc 30 - 70 kts Full flaps operating range Lower limit: Vso at maximum weight in landing configuration Upper limit: maximum speed permissible with flaps extended

Green arc 40 – 98 kts Normal operating range Lower limit: Vs at maximum weight with flaps retracted Upper limit: maximum structural cruising speed

Yellow arc 98 – 123 kts Operations must be conducted with caution and only in smooth air

Red line 123 kts Maximum speed for all operations

5.2 WEIGHT LIMITS AND FLIGHT LOAD FACTOR LIMITS Maximum take-off weight 1 150 lbs (523 kg)

Flight load factors (limit): * flaps up +4.0 / -2.0 G * flaps down +2.0 G * Design load factors are 150% of the above

5.3 CENTER OF GRAVITY LIMITS Center of gravity range: Forward 8.0 inches aft of datum (20,3 cm) Aft 13.2 inches aft of datum (33,5 cm) Reference datum:wing leading edge




6 WEIGHT AND BALANCE It is mandatory that you check the weight and balance of your aircraft before flight-testing. The Pelican was designed to minimize the risk of exceeding the limits of the weight and balance envelope if properly built and loaded. However, if the center of gravity is not well located versus the wing chord, the flight characteristics of your aircraft might be dangerously altered: • If the C.G, is too far forward, you will lack elevator power on landing • If the C.G. is too far aft, the aircraft will be unstable and dangerous to fly

6.1 WEIGHT AND BALANCE CHECK 1. Place the aircraft on three scales. 2. FIRST: Check the position of the center of gravity with the empty aircraft (no fuel, no baggage,

no passenger). Make a list of the equipment and note if there is oil and coolant. 3. SECOND: Check the foremost position of the center of gravity (light pilot, no fuel, no baggage) 4. THIRD: Check the rearmost position of the center of gravity (2 pilots, full fuel, full baggage). 5. You may also check the weight and balance of your aircraft in any other loading condition by

measuring the weight, computing the moment and checking the new figure with the weight and balance envelope.




6.2 PROCEDURE, SAMPLE CALCULATION AND DATA

DATA:

• Place the aircraft on 3 scales • The aircraft must be level (rear top of fuselage is level) • Take note of the Lnose and Lmain measures (note the distance between the plumb line shown

below and the center of the wheel axles) • Write these figures in Table 1




EMPTY WEIGHT C.G.

• Read the weight on each scale and write them down in Table 1 • Add up the weights and moments. Write the totals in Table 1

Sample calculation: Lnose -32.75 in Lmain 22.75 in Wnose 185 lbs Wmain, right 220 lbs Wmain, left 220 lbs Wmain, total 440 lbs W total 625 lbs Lnose x Wnose -32.75 in x 185 lbs = -6059 lbs-in Lmain x Wmain 22.75 in x 440 lbs = 10010 lbs-in MOMENT = Lnose x Wnose + Lmain x Wmain = -6 059 in-lbs + 10 010 lbs-in = 3 951 lbs-in VERIFICATION 3 951 lbs-in = 6.32 inches 625 lbs 6.32 inches / 44 inches = 14% of wing chord Note: If aircraft is taildragger, Ltail x Wtail is + sign




6.3 WEIGHT AND BALANCE CALCULATIONS TABLE 1 (1) Lnose = _________________ (minus sign if tricycle)

(2) Lmain = _________________

( A ) EMPTY WEIGHT C.G. A

(3) Weight under the nosewheel: Wnose (4) Weight under left wheel: Wmain, left (5) Weight under right wheel: Wmain, right (6) Total weight under main wheels: Wmain (4 + 5) (7) Total weight of aircraft: WT (3 + 6) (8) Lnose x Wnose (2 x 3) (9) Lmain x Wmain (1 x 6)

(10) Moment (8 + 9)

This is your empty weight C.G. If you add equipment, you may weigh the equipment, measure the distance from the datum and compute your new empty weight C.G. without weighing the airplane. ( B ) FOREMOST C.G. ( C ) REARMOST C.G. B C

(3) Weight under the nosewheel: Wnose (4) Weight under left wheel: Wmain, left (5) Weight under right wheel: Wmain, right (6) Total weight under main wheels: Wmain (4 + 5) (7) Total weight of aircraft: WT (3 + 6) (8) Lnose x Wnose (2 x 3) (9) Lmain x Wmain (1 x 6)

(10) Moment (8 + 9)

Check that the total Weight (7) and Moment (10) coordinates fall within the envelope of the next page with the loaded aircraft.




WEIGHT AND BALANCE ENVELOPE

6000 8000 10000 12000 14000 16000 lbs-in

990 , 7920

1100

750, 6000 750, 9900700

800

900

1000

lbs1150 , 10800 1150, 15180

1150

( B ) Weight of the aircraft: foremost position • Load the aircraft with one light pilot, no fuel and no baggage • Take note of the weight on each scale • Compute the weight and moment and check that the coordinates fall in the envelope ( C ) Weight of the aircraft: rearmost position • Repeat operations with 2 pilots, full fuel and full baggage




7 NORMAL PROCEDURES

7.1 PRE-FLIGHT INSPECTION Before each flight, the operator must visually inspect the aircraft, as taught in every good flying school. The following checklist can be used as guide:




0. Before external verification: documents and licenses 1. Unfasten seat belts to free the controls Electrical system = OFF Fuel selector: ON 2. Door fasteners, window, struts and fairings, landing gear, brakes, wheel pants, wheels and tires.

Leading edge and wing gap cover in good condition. Remove pitot cover (left side). If wing tanks: drain, visual check of fuel level, check for leaks.

3. Struts, leading edge 4. Wing tip: check screws and mass balance 5. Ailerons and flaps, including controls and fittings. No unusual play. Fabric, false spar and ribs in

good condition. 6. External check of airframe 9 to 12 Same as 2 to 5 13. Windshield in good condition. Cowling secured. Propeller is in good condition. No unusual play

in gearbox. Winter: Check installation of radiator and oil cooler winter kit Engine access door: nothing unusual. Check oil and coolant expansion bottle. 14. With ignition OFF: Turn propeller by hand and observe engine for odd noises or uneasy

movements and proper compression 15. Cabin: visual check of cables, pulleys and supports, engine mount bolts, pedals, brakes. sticks,

instruments, fuel selector, seat belts, door hinges, etc...




7.2 ENGINE PRE-START VERIFICATION Fuel selector ON Master OFF Electricals and radio OFF Trim NEUTRAL Throttle IDLE (note: if throttle is cracked, choke is inoperative) Choke as required

7.3 START After having looked around the aircraft Master ON Alternator OFF (check light is on) Brakes applied Start while looking outside. Activate starter for max 20 sec only, followed by a cooling period of 3 minutes Reduce engine RPM as required (2000 - 2500 RPM for warming up) Check engine oil pressure: pressure has to rise within 10 seconds Alternator: check light is off

7.4 CHECK BEFORE TAXIING Check instrument panel from left to right and top to bottom Choke as required Flaps: up

7.5 TAXI Try the brakes Aircraft with nose in the wing for the run-up




7.6 RUN-UP OF PRE-TAKE-OFF CHECK Engine • Check traffic behind • Pressure and temperature (oil has reached 120°F) • Choke: OFF • Check ignition circuits as per engine operator manual • RPM: idle Instruments and accessories • Compass • Fuel selector ON • Alternator (light is off) • Check instrument panel from left to right and from top to bottom Controls • Controls Free • Flaps Take-off position • Trim Neutral Safety • Seat belts • Baggage secured • Doors locked • Check traffic • Radio call




7.7 TAKE-OFF • Climbing with engine running at peak performance is permissible • Note RPM • Observe oil temperature, cylinder head temperature and oil pressure

7.8 ENGINE STOP In normal conditions, the cooling down of the normally aspirated Rotax engine during descent and taxiing will be sufficient to allow to stop the engine by switching the ignition OFF




AIRFRAME MAINTENANCE GUIDE

1 MAINTENANCE OF COMPOSITE - General The fuselage and engine cowlings of the Pelican are made from vacuum molded composite materials, which consist in fiberglass and vinylester resin with a polyvynil chloride (PVC) foam core. These materials are cured at room temperature. The composite materials require very little maintenance. It is however important that the structure should be regularly checked for delaminations, particularly in case of accidents. A visual check is usually enough to find failures in the composite materials. Any crack, lump, depression or soft surface should be investigated and repaired. For this, refer to the introductory section of the Pelican assembly manual. The composite materials used in the Pelican are stable at outside temperatures ranging from -40°C to +50°C (-40°F to 120°F). Tolerable surface temperature can however reach over 80°C (180°F). The color of the fuselage is normalized white, which prevents any risk of surface temperature going beyond these values. The operator is authorized to paint identification marks and side decorative bands of any color. There is no restriction on the color of the covering fabric. Composite materials are also sensitive to ultra-violet rays. The Pelican resin system uses an additive for UV protection. However, a coat of paint, preferably polyurethane, should protect composite parts.




2 MAINTENANCE OF FABRIC - GENERAL The fabric must be well protected from ultra-violet rays. After bonding the fabric to the frame and taughtening it with the iron, the fabric should be cleaned, covered with a good UV barrier. The operator is referred to the « covering » section of the Pelican assembly manual. The fabric should be checked regularly. It must be well bonded to the structure and cuts or rips must immediately be repaired. Depending on exposure to the sun, the fabric will deteriorate with time and re-covering will then be required. Experienced mechanics in covering have a special tool to check if the fabric is in good shape or deteriorated.

3 HARDWARE The hardware used in the construction of the Pelican (bolts, nuts, cable, turnbuckles, pulleys) is almost exclusively of aeronautical type (AN, MS or NAS) and treated against corrosion with nickel-cadmium plating. However, rubbing and exposure to wind and rain may remove this protection and rust will appear. It is then recommended to change the part to prevent corrosion from spreading. The shackles, clevis pins and safety pins should namely be changed regularly. As a general rule, for all bolts, the operator should see 1 to 3 threads exceeding the nut. Bolts which are too short should be changed for longer bolts and washers should be added for bolts slightly too long. The operator should regularly check that the nicopress on the cables are in good condition and that the tension in the cables is adequate. The cables should also be secured in the pulleys, with no excessive play. The pulley supports (cabin and wings) should be checked regularly for failures.




4 MAINTENANCE OF STEEL PARTS - General A number of parts in the Pelican are made of steel, namely the landing gear, the engine mount, the sticks and pedals, the fin post, the tailfeather horns, some push-rods, etc... All steel parts must be protected against the rust at the assembly stage (sanding with fine grit paper, linseed oil inside tubes and steel primer on the outside). Steel parts must also be checked and cleaned regularly. Some parts, such as the fin post and the wheel axles, must be taken off and greased regularly. All steel parts should be checked regularly for failures, namely at the welds.

5 MAINTENANCE OF ALUMINIUM PARTS - General As specified in the Assembly manual, the aluminium used in the construction of the Pelican is of 2024-T3 Alclad grade for sheeting and of 6061-T6 grade for tubing and extrusion. These materials already offer a good protection against rust. It is however recommended to the treat the aluminium with specialized products (such as zinc chromate of vinylwash primers) for marine or salt water operations. All exposed aluminium parts should be cleaned, primed and painted. All aluminium parts should be regularly checked for failures, such as cracks and crushed areas.

6 ACCESSORIES - General The operator should regularly check all accessories and make sure of their proper state of operation. Particular care should be given to the brakes, the instruments and the accessories in the engine compartment (electrical system, fuel system, exhaust system, cooling system, battery, spinner, propeller, etc...).




MAINTENANCE SCHEDULE

1 Check before first flight: As per conformity inspection

2 Check after initial 10 hours: Something may have been overlooked before the first flight, some bolts may need tightening, some SS screws may have flown away, some wires may be rubbing in the engine compartment, you may have some dirt in the fuel tanks, etc.

General inspection of engine compartment:

• 25 hour inspection from Rotax manual, except for oil and oil filter change • Engine tight (inspect Lord mounts and bolts) • Exhaust system: secured to engine • Hoses, wires, lines secure (no wear by friction) • Change fuel filter • Clean gascolator • Check carburators and filters for security • Check propeller blade pitch and bolts torque • Check fuel line connections • Check cooling system, including hoses and clamps

General inspection of airframe:

• Remove all fairings and covers to inspect all bolts (landing gear, struts, wings to fuselage, empennage supports, sticks, etc.) for security

• Check control cables tension / no chaffing / no slip • Check presence of all Cotter pins • Check brakes: mount leg on support and check that the wheel turns freely • Check all SS screws (fairings and others) for security • Check no friction / no play in all control surfaces

Others: Any vibration must be investigated




3 Check after initial 25 hours Engine: 25 hours from Rotax engine manual + change fuel filter Check spark plugs for color Perform compression test (the engine should be run-in and this will be your

reference compression values) Others: Same as 10 hour inspection

4 Check at every 50 hours Engine: As per Rotax manual - 100 hour inspection Change fuel filter Clean spark plugs (or change) + gap Inspect and lubricate nosewheel nylon bearings Airframe inspection: General

5 100 hours or annual inspection:

CONFORMITY INSPECTION


50 HOUR INSPECTION CHECK-LIST



AIRCRAFT IDENTIFICATION: Pelican serial N° _____________________ Engine model ______________________ Registration _____________________ Engine serial N° ______________________ Airframe total time _____________________ Engine total time ______________________ Propeller model ______________________ Propeller serial N° ______________________ Owner: ________________________________ Satis Unsatis Fixed GENERAL Registration / C of A Weight and Balance / Equipment list WINGS Remove inspection plates / fairings General inspection of the exterior/interior of wing Flight control proper attachment (free / no slop) Flight controls properly rigged / proper tension Inspect all control stops for security Skin panels delaminate / voids Popped rivets / cracked / deformed skins Fabric/tape condition Lubrication (WD40 on bushings) Wing attach points Struts for security Corrosion Check drains ____________________________________________ ____________________________________________ FUEL SYSTEM Corrosion Fuel lines for chaffing/leaks/security/condition Fuel caps for security Fuel placards Fuel valve / cross feed for operation and security Inspect fuel tank vent system ____________________________________________





Satis Unsatis Fixed FUSELAGE Inspect for delaminated skin and voids (in and out) Inspect door latching mechanism Inspect rudder pedals/brakes for operation/security Inspect behind firewall for loose wires/chaffing lines Check control sticks for freedom of movement / no play Check flap control operation Check cables and pulleys for security and operation Inspect instruments, lines, for security / clean Inspect seats, seatbelts/shoulder harness for security and attachment Corrosion check Check drains _____________________________________________ _____________________________________________ LANDING GEAR Remove fairings Inspect legs for attachment / tighten Allen bolts Check all bushings for wear / free play Wheels/tires for cracks and serviceability Inspect for corrosion Inspect nosegear/tailwheel for cracks and travel / Lubricate nylon bearings and push-rods

Check tire pressure Brake linings within limits Brake disks for cracks/wear/deformity Brake hydraulic lines for leaks and security (use only automatic transmission oil) ____________________________________________ ____________________________________________ TAIL Inspect rudder attachment points Inspect elevator/stabilizer attachment points Inspect hinges/trim tab for attachment and free play Inspect skins for damage/corrosion Inspect all control cables, hinges and pulleys Lubrication (WD40 on bushings) Inspect all control stops Check drains __________________________________________





Satis Unsatis Fixed ENGINE Change oil and filter (check for metal) Inspect ignition harness for condition and continuity Check ignition leads cigarettes for condition/cracks Clean (change) and gap spark plugs Inspect engine mount/bushings Check torque of engine mount attachment bolts Inspect cylinders for cracks/broken fins/exhaust stains Check for oil leaks Inspect oil vent lines Inspect carburator for security/clean filters Inspect throttle/choke control for proper travel and security / Lubricate Inspection condition of flexible fuel and oil lines Inspect oil cooler for leaks and condition Check exhaust system for attachment and condition Check muffler for security and attachment Check cowling for cracks and security Check radiator/hoses for leaks/security + anti-freeze Check radiator/oil cooler covers for winter operation _________________________________________ _________________________________________ _________________________________________ PROPELLER Check spinner and backplate for cracks Inspect for cracks / stone damage / nicks (DO NOT FILE) Repair nicks (resin) - Paint/varnish Check for delaminations Check prop bolts torque / Safety wire Check for oil leaks (crankcase nose seal) ___________________________________________ ___________________________________________ ELECTRICALS Battery and supports/covers for security/corrosion Check position/strobe lights for operation Check all antenna mounts and wiring for security Inspect radios/leads/wires for attachment and security Inspect circuit breakers/panel for condition __________________________________________





OPERATIONAL INSPECTION Satis Unsatis Fixed Visual inspection of the engine/propeller All inspection panels and fairings secure Brake system check Proper fuel in tanks (Super unleaded or 100LL with TCP additive) Engine start procedures Oil pressure/oil temperature within limits Ignition check Idle RPM check/Choke check Static RPM check Electrical system check Cool down period/engine shut-down Perform oil, hydraulic and fuel leak check _____________________________________________ PAPERWORK Airworthiness directives Record findings and sign off inspection and maintenance in aircraft logbooks _____________________________________________ Inspector signature: ___________________________________ Name (in print) ___________________________________ Date: ___________________________________

PELICAN SPORT 450 S



6 WINTER OPERATION Ultravia offers a very effective cabin heating system with radiator. However, you will not get adequate heating if the engine’s water temperature is too low. For winter operation: • Check prestone • Check acid in battery • Install fiberglass radiator cover (or cover partly with tape) when outside temperature is below 50°F

(10°C) • Install Lexan cover (drill a few holes in the cover) over oil cooler when oil temperature falls below

green arc

DAMAGE TO THE ENGINE OR ENGINE STOPPAGE CAN OCCUR IF TEMPERATURES ARE NOT

WITHIN OPERATING LIMITS OR IF THE AIR COMING FROM THE CABIN HEATING SYSTEM IS NOT WARM ENOUGH

Comes spring and summer, you must remove the fiberglass covers in the radiator and oil cooler inlets. You may also disconnect the air hose from the side of the cabin to the radiator box and connect directly from the side of the cabin to the ventilation box behind the instrument panel.




CONFORMITY INSPECTION CHECK-LIST This list was put together as a guide to the Pelican operator. It must in no case be considered as a complete and infallible list. The assembly manual is a far better guide and each owner and operator must ensure that he has the required knowledge and competency to perform a valid inspection. This guide is also very useful before the first flight of the aircraft. In the event the aircraft should be flight tested by another person than the owner, we remind the latter that the whole responsibility of declaring the aircraft airworthy lies with the owner who bears the sole responsibility of any accident or incident, which may be related to the construction of his aircraft. Human lives are at stake, not to mention the amount of time and money involved. It is therefore of capital importance that you do a thorough inspection of your aircraft before declaring that it is airworthy.




AIRCRAFT IDENTIFICATION: Pelican serial N° _____________________ Engine model ______________________ Registration _____________________ Engine serial N° ______________________ Airframe total time _____________________ Engine total time ______________________ Propeller model ______________________ Propeller serial N° ______________________ Owner: ________________________________ Satis Unsatis Fixed GENERAL Registration Aircraft identification plates and placards installed Weight and Balance / Equipment list WINGS Remove inspection plates / fairings General inspection of the exterior/interior of wing Flight controls balance weights for security Flight control proper attachment (free / no slop) Flight controls properly rigged / proper tension Check aileron travel Check flaps operation Inspect all control stops for security Skin panels delaminate / voids Popped rivets / cracked / deformed skins Fabric/tape condition Lubrication (WD40 on bushings) Wing attach points Struts for security Corrosion Pitot line / electrical wires and connectors Check drains ____________________________________________ ____________________________________________




Satis Unsatis Fixed FUEL SYSTEM Corrosion Fuel lines for chaffing/leaks/security/condition Sump all tanks for water or debris Fuel caps for security Fuel placards Fuel valve / cross feed for operation and security Change fuel filters / clean gascolator / flush system Inspect fuel tank vent system ____________________________________________ ____________________________________________ Satis Unsatis Fixed FUSELAGE Remove pulley covers, console top, cable covers Inspect for delaminated skin and voids (in and out) Inspect bulkheads for cracked skins Inspect windows for cracks and fit Inspect windshield for cracks and fit Inspect door latching mechanism Inspect firewall for distortion and cracks Inspect rudder pedals/brakes for operation/security Inspect behind firewall for loose wires/chaffing lines Check control sticks for freedom of movement / no play Check flap control operation Check cable and pulleys for attachment and operation Check aileron cables tension: 50 lbs Ensure cockpit instruments are properly marked Compass swing (annual) Inspect instruments, lines, for security / clean Inspect cockpit fresh air vents / heater for operation and security Inspect seats, seatbelts/shoulder harness for security and attachment Corrosion check Check drains _____________________________________________ _____________________________________________




Satis Unsatis Fixed LANDING GEAR Remove fairings Inspect legs for attachment Lift wing and check leg for play / grease pivot points / tighten bolts Check all bushings for wear / free play Lubricate wheel axles / Check security of bolts Inspect wheels for alignment / balance Wheels/tires for cracks and serviceability Wheel bearings for lubrication/wear Inspect for corrosion Inspect nosegear/tailwheel for cracks and travel / Lubricate nylon bearings and push-rods

Check tire pressure Brake linings within limits Brake disks for cracks/wear/deformity Brake hydraulic lines for leaks and security (use only automatic transmission oil) ____________________________________________ ____________________________________________ ____________________________________________ TAIL Remove covers and fairings Inspect vertical fin attachment points Inspect rudder attachment points Inspect elevator/stabilizer attachment points Inspect hinges/trim tab for attachment and free play Inspect skins for damage/corrosion Inspect all control cables, hinges and pulleys Check table tension: 50 lbs elevator, 20 lbs rudder Check elevator travel Check rudder travel / No interference with elevators Lubrication (WD40 on bushings) Inspect all control stops Flight control balance weights for security Check drains __________________________________________ __________________________________________ __________________________________________




Satis Unsatis Fixed ENGINE Perform compression test (yearly or 100 hrs) #1 __________ #2 ___________ #3 __________ #4 __________

Change oil and filter (check for metal) Inspect ignition harness for condition and continuity Check ignition leads cigarettes for condition/cracks Clean (change) and gap spark plugs Inspect engine mount/bushings Check torque of engine mount attachment bolts Inspect cylinders for cracks/broken fins/exhaust stains Check for oil leaks Inspect oil vent lines Inspect carburator for security/clean filters Oil air filters Change carburator intake flanges (200 hrs or yearly) Inspect throttle/choke control for proper travel and security / Lubricate Inspection condition of flexible fuel and oil lines Inspect oil cooler for leaks and condition Check exhaust system for attachment and condition Check muffler for security and attachment Check cowling for cracks and security Check radiator/hoses for leaks/security + anti-freeze Check radiator/oil cooler covers for winter operation _________________________________________ _________________________________________ _________________________________________ _________________________________________ PROPELLER Check spinner and backplate for cracks Inspect for cracks / stone damage / nicks (DO NOT FILE) Repair nicks (resin) - Paint/varnish Check for delaminations Check prop bolts torque / Safety wire Check for oil leaks (crankcase nose seal) Check prop track/pitch ___________________________________________ ___________________________________________ ___________________________________________




Satis Unsatis Fixed ELECTRICALS Battery serviced and free of corrosion Battery supports/covers for security/corrosion ELT battery free from corrosion and current battery Check position/strobe lights for operation Check all antenna mounts and wiring for security Check all grounding wires (engine to airframe, wing, tail, etc...) Inspect radios/leads/wires for attachment and security Inspect circuit breakers/panel for condition __________________________________________ __________________________________________ OPERATIONAL INSPECTION Visual inspection of the engine/propeller All inspection panels and fairings secure Personnel with fire bottle standing by Brake system check Proper fuel in tanks (Super unleaded or 100LL with TCP additive) Engine start procedures Oil pressure/oil temperature within limits Ignition check Idle RPM check/Choke check Static RPM check Electrical system check Cool down period/engine shut-down Perform oil, hydraulic and fuel leak check _____________________________________________ PAPERWORK Airworthiness directives Record findings and sign off inspection and maintenance in aircraft logbooks _____________________________________________ Inspector signature: ___________________________________ Name (in print) ___________________________________ Date: ___________________________________

ballard sport aircraft ltd. · ballard sport aircraft ltd. pelican sport 450 s 5 ... instruments...

Documents